JGI - Presentation 25-April 2013

L&T Heavy Engineering
Manufacturing & Machining Facility

at Badlapur Production Centre (BPC)
Location – John Galt International, MIDC, Badlapur

Facility F2 – Manufacturing (PC3)
Facility B21 – Machining (PC4)
26 Mar 2013 © 2011 Larsen & Toubro Limited : All rights reserved 1 of 45
Facilities at John Galt-MIDC, Badlapur
Plot B21 (M/c Shop)

Plot Size: 2400 m2
Covered Area: 2100 m2
Plot B6 (Warehouse,
CMF & M/c)
Plot Size: 4400 m2
Plot F2 (Fabrication Shop)

Plot Size: 25000 m2
26 Mar 2013 © 2011 Larsen & Toubro Limited : All rights reserved 2
John Galt, Badlapur –Facilities

Plot F2 • Area under shed 9900 m2 + Open Area
~10000 m2 (usable) + 5 Buildings ~ 5100 m2
(Total Area
25000 m2) • Allocated for Main Fabrication Shop
Plot B21 • Area under shed ~2100 m2

(Total Area- • Allocated for Machine shop
2400 m2)
• Area under shed ~3000 m2 + Open Area ~ 1100m2

Plot B6 + Building ~ 300 m2
(Total Area • One Bay (1500 m2) + Open Area Allocated for store
4400 m2) • One Bay (1500 m2) for CMF & m/c.
Plot “F2” – Manufacturing Shop
26 Mar 2013 © 2011 Larsen & Toubro Limited : All rights reserved
4
Facility at Plot “F2”- Manufacturing Shop
Total Area
Covered POWER
Bay 1 Bay 2 Bay 3 (Open &
Area - m2 Connection
Covered)
BAY
158 L x 21 W 158 L x 23 W 142 L x 21 W 9900 25000 m2 200 KVA existing+
SIZE
New 500 KVA.
25T – 2 nos DG Back-up Exist.
CRANES 10 T - 3 nos 10T – 3 nos 125 KVA+ Addnl.
10 T – 1 no.
315 KVA
5
Facility at Plot “F2”- Manufacturing Shop
14.0 m
12.5 m
(Under
Hook Ht)
Bay 2L Bay 3L
Bay 1L 11 m
9.50 m (Under
Hook Ht)
Bay 1 Bay 2 Bay 3
Floor at two levels 21 m 23.5 m

21 m
Bay 1 / 1L Bay 2 / 2L Bay 3 / 3L

BAY SIZE
162 L x 21 W 162 L x 23.5 W 140 L x 21 W
CRANE S 10 T - 3 nos. 25T – 2 nos., 10T-1 no 10T – 3 nos.
6
Plot “F2” – Manufacturing Shop
F2 - Plant Layout wrt

Flow is Finalized.
7
F2 Plant Status NDE Block

 NDE Block Ready (RT/UT processing, TPI room, Dark Room) Civil,
Electrical, furnishing completed.
NDE BLOCK
8
F2 Plant Status RT Enclosure
 RT Enclosure - Civil, Electrical work Completed.
 BARC Authorities inspection completed on 22 Mar’13.
9
F2 Plant Status
Welding Consumable Store, Hot Room
Welding Consumable Stores, Hot room Ready.
10
F2 Plant Status Main Stores, Excise Office
Main Stores, Excise room work completed.
Toilet commissioning in progress.
11
F2 Plant Status Water Storage Facility
Underground Water Storage Tank (2.6 Lac Liter) completed.
12
F2 Plant Status Concreting of Lower Bays
 Bay 1 (Lower) flooring in progress.
Levelling with soil completed,

Laying of rubble in progress
13
F2 Plant Status F2 - Plant Office
 Civil work of Plant office (Admin Block) completed
 Electrical, Furnishing work completed.
 Compound Wall, Entry Gate to Office renovation completed.
 Painting completed & finishing will be completed by 30 Apr’13.
14
F2 Plant Status F2 - Plant Office
 Garden at the entrance of Plant office (Admin Block).
15
F2 Plant Status Electrical, LAN, Telephone Cabling
 Server Room, EPABX for Telephone lines commissioned.
 Installation of Hume Pipes for Electrical/LAN, BSNL Cable completed.
construction of drainage in progress.
Drainage construction completed, grid covering balance
16
F2 Plant Status Development of outside area
 Surrounding Plot Survey done.
 Landscape/leveling/roads finalized by Structural Consultant.
Levelling completed, Road construction in progress

Levelling of
plate yard
Retaining wall constr.

F2 Plant Status Development of Facilities
 Plant, Crane Support Structure, Building inspection done by L&T
Structural Consultant.
 L&T Safety Audit Points are being implemented.
 Access road leveling for trailer movement/ entry into shops/exit
from F2 examined by L&T Logistics, Transporters.
 Workmen Cloak rooms Layout finalized, 80 Lockers received.
 Canteen/Dining Area Allocated.
 Overhead Water Tanks for Drinking/Sanitation(37,000 Liters)
already commissioned.
 Underground drinking/sanitation water piping work in progress.
18
 Canteen / Dining Area for workers.
Tables
arranged
19
Slab laying completed
Toilets for
Workmen in
progress
Primer coating for

security cabin and
initial plastering
completed for
Temple.
20
F2 Plant Status LAN Connectivity with Powai
 LAN Tower from Bharti Airtel installed, RF Commissioned.
 Connectivity with Powai Server already established.
 Connectivity between 3 locations i,e,F21, B21, B6 established.
18 m Tall Mast over F2

Building Terrace
Interconnecting
Tower F2, B21, B6
21
F2 Plant Status Planning of WTC/First Aid Facility
 Old existing structure demolished, Plan for WTC/First Aid/ Training
room /Cylinder Storage finalized and digging for column is i/p.
 Exploring CNG Piping inside F2 to eliminate Gas Cylinders.
22
F2 Plant Status Readiness for Manufacturing
 Bay- 1, 2 & 3 - Upper areas vacated and cleaned.
 CMF piping work from R&C-Shop2 shifted to Bay-2, Upper area
 Bay-3, Lower earmarked for Nuclear jobs. Planning the partitioning of
the Bay-3 Lower side.
Bay 1 - Upper Bay 2 - Upper Bay 3 - Upper
23
F2 Plant Status Construction -Electrical Sub-Station
 MSEB Permission for increased Power received / DG set ordering
completed.
 Civil work for Electrical Sub-Station in Progress.
 Full Power 200+500 KVA; DG set 125+315 KVA by 30 May’13.
New DG installed
24
F2 Plant Status Readiness Milestones
Sr.
Action Plan (phase - 1) Target Dates Current Status
No.
1 JGI to get Bay-2 vacated and release three buildings. 15-Jan-2013 Completed
2 JGI to get open Area and one buildings. 28-Feb-2013 Completed
NDE Block/Dark Room, Welding Consumable
3 stores/Hot Room, Cleaning , Lighting in shop top side 28-Feb-2013 Completed
Bay - 2 for ASME Audit.
RT Enclosure (Civil, Electrical) work completed.
4 15-Mar-2013 Completed
BARC Audit completed on 22 Mar’13 Satisfactorily.
5 Enhance Power Supply 500KVA, DG Set 315 KVA 15-Mar-2013 Sanction Recd
LAN connection & Movement of contractors,
6 Machines, Tools, Tackles and Start component 15-Mar-2013 Completed
manufacturing of “Non-AI /IBR “ jobs
JGI to get Bay-3 Upper & Lower vacated. Fencing /
7 15-Apr-2013 In progress
Painting / Lighting of Buildings/shops as required.
Planning
8 Cloak Rooms, Toilet, Leveling of Open Area, roads 15-May-2013
completed
9 ASME Audit of the Facility, Start ASME jobs 10-June-2013
25
F2 Plant Status Major Infrastructure Enhancement
Sr. Current
Action Plan (Phase -2) Target Dates
No. Status
1 Concreting of Shop Floor –Bay -2 - Lower side 30 Mar 2013 completed
Installation of New Power connection- 500 KVA &
30 May 2013 Started
2 DG Set – 315 KVA
Levelling of land, concreting of rail area for Gantry
3 Installation of Gantry Crane, Shot Blasting & 30 Jun 2013 in progress
painting Shed - 8 W x 8 H x 20 L
4 Installation of Gantry Crane 30 Sept 2013 Planned
Sr. Current
Action Plan (Phase – 3) Target Dates
No. Status
1 Concreting of Shop Floor - lower Bay 1 30 Apr 2013 In Progress
2 Levelling of Open Area - remaining 30 May 2013 In Progress
3 Approach Road & Surrounding Lighting 8 June 2013 In Progress

4 25 T Cranes - 2 nos. & Inter bay transfer Trolley 30 Sept 2013 Planned
26
Facility at Plot “B21” – Machining Shop
27
Facility at Plot “B21”Machining Shop
Covered Total Area

Bay 1 Bay 2 Power Connection
BAY Area (Open & Covered)
SIZE 58 L x 18 W 58 L x 18 W 2100 m2 2400 m2 200 KVA500KVA
with DG Back-up
CRANES 10 T - 2 Nos 10T – 2 Nos 125KVA315 KVA
28
B21 Plant Status Facility at Plot “B-21” – Machine Shop
B21 - Plant Layout wrt

Flow is Finalized.
29
B21 Plant Status Foundation laying for Machines
Bay-1, Pit for foundation of DHD,VTL & CNC-VTL completed.
Shop Fencing Wall Constructed. HMC commissioning in progress
HMC Commissioning 5-axis Foundation
Bay - 1 Boundary Wall
B21 Plant Status Installation of Drilling Machines
 Installation of 3 radial drilling M/cs in Bay-2 in progress.
 HMC, VTL, Lathe M/c’s planned to be shifting completed,
commissioning in progress.
Tiles polishing in progress
Radial Drilling Partition
Lathe Machine
Foundation in progress
B21 Plant Status Power Upgradation
 Power Sanction 200 to 500 KVA obtained. DG 300 KVA installed.
B21 Plant Status
Gangway marking
Front Roof
Tool Storage
B21 Plant Status Vacating/Cleaning of Bay - 2
 Civil work of Main office, Partition wall and Toilets in progress.
Main Office painting work Toilet for staff

in progress
Partition wall between 2 bays

construction in progress
B21 Plant Status Readiness Milestones
Sr. Target Current
Action Plan
No. Dates Status
1 JGI to get Bay-1 vacated from existing contractor 15-Dec-2012 Completed
2 Readiness of Foundation of DHD 20-Feb-2013 Completed
3 Foundation work for CNC-VTL, VTL 30-Mar-2013 Completed
4 JGI to get Bay-2 vacated from existing contractor 15-Apr-2013 Completed
5 Drilling Machines (6 out of 15) in operation 30-Apr-2013 Completed
Up-gradation of Power 200 to 500KVA; DG-125 to 300 KVA
6 Electrical connections / painting / lighting / air ventilators / 30-Apr-2013 Sanction
front Shed / boundary wall height of Bay-1 &2 Received
7 Installation of remaining drilling machines (9 nos.) 30-Apr-2013 In Progress

8 Installation of HMC, CNC VMC (2 Nos), Lathe (4 nos) 15-May-2013 In progress
9 Dismantling, Shifting, Install. Commissioning of VTL 31-May-2013 In progress
Dismantling, Shifting, Install. Commissioning of CNC-VTL,
10 15-Jun-2013 Planned
DHD **
Facility at Plot “B6”
36
Facility at Plot “B6”
Covered Total Area Power

Bay 1 Bay 2
Area (Open & Covered) Connection
BAY SIZE 80 L x 18 W 80 L x 18 W 3000 m2 4400 m2 200 KVA with
125 KVA DG
CRANES 10 T - 2 nos 10T – 2 nos Back-up
37
Facility at Plot “B-6” – Warehouse & CMF, M/c Shop
B6 - Plant Layout wrt

Flow is Finalized.
38
B6 Plant Status Vacating/ Cleaning of B6, Bay 2
 Bay-2 being vacated, cleaning/painting of structures started.
39
B6 Plant Status New Metallic Roofs installed
 Plant Structural inspection done by L&T Structural consultant
40
B6 Plant Status New Metallic Roofs installed
Electrical old cables removed, laying of new cables in progress
41
B6 Plant Status New Metallic Roof/side panels
 Partition completed, Structural Column repairs completed
42
B6 Plant Status New Metallic Roof/side panels
 Shop roof, side Asbestos sheets replacement by Galvanized sheets.
43
B6 Plant Status Electrical Sub-Station
 Repair of Electrical Sub-station room completed
44
B6 Plant Status Earthing Pit in B6
Earthing pit revamping completed
45
B6 Plant Status Readiness Milestones
Sr. Current
Action Plan Target Dates
No. Status
Finalise contract for operations of Stores & LAN
1 30-Nov-2012 Completed
Connection.
JGI to get Bay-1 + Open area vacated from Existing
2 15-Dec-2012 Completed
Contractor .
Partition between Bay-1 & Bay-2, Storage Racks,
3 20-Dec-2012 Completed
Overhead Lights, Security arrangement.
4 Readiness of the Warehouse- BAY-1 15-Jan-2013 Completed
5 JGI to get Bay-2 vacated and cleaned. 30-Mar-2013 In Progress

Electrical connections, lighting, floor cleaning
6 30-Mar-2013 In Progress
painting.
7 Installation and commissioning of Lathe/Rolling M/c 30-May-2013 In Progress

Contractor mobilisation for Warehouse . 1- Feb-2013/ Started/
8
Machining of jobs to start. 1-June-2013 Planned
46
BPC Status Logistics & Facilities
• Bus from Thane (W) to JGI Badlapur (48 kms)
Transportation for
• Shuttle Service, between Badlapur Station & JGI and
L&T staff
between Powai & JGI.
Transportation for
• Train
Contractors’
Workmen
• First aid centre inside F2 Plant
• Hospitals – ESIC attachments
Medical Facility
• Attachment to Private Hospitals- Dhanavantari, Fortis
• Ambulance – 24x7 Basis
• Emergency Preparedness Plan will be made in
Force Majeure
consultation with Safety department.
47
Thank You
48

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L&T Heavy Engineering

Manufacturing & Machining Facility

Location – John Galt International, MIDC, Badlapur

Plot B21 (M/c Shop)

Plot F2 (Fabrication Shop)

John Galt, Badlapur –Facilities

Plot B21 • Area under shed ~2100 m2

• Area under shed ~3000 m2 + Open Area ~ 1100m2

Plot “F2” – Manufacturing Shop

Floor at two levels 21 m 23.5 m

Bay 1 / 1L Bay 2 / 2L Bay 3 / 3L

F2 - Plant Layout wrt

F2 Plant Status NDE Block

Levelling with soil completed,

Drainage construction completed, grid covering balance

Levelling completed, Road construction in progress

Retaining wall constr.

Primer coating for

18 m Tall Mast over F2

Bay 1 - Upper Bay 2 - Upper Bay 3 - Upper

3 Approach Road & Surrounding Lighting 8 June 2013 In Progress

Facility at Plot “B21” – Machining Shop

Covered Total Area

B21 - Plant Layout wrt

HMC Commissioning 5-axis Foundation

Bay - 1 Boundary Wall

Radial Drilling Partition

Main Office painting work Toilet for staff

Partition wall between 2 bays

7 Installation of remaining drilling machines (9 nos.) 30-Apr-2013 In Progress

Facility at Plot “B6”

Facility at Plot “B6”

Covered Total Area Power

B6 - Plant Layout wrt

 Plant Structural inspection done by L&T Structural consultant

5 JGI to get Bay-2 vacated and cleaned. 30-Mar-2013 In Progress

7 Installation and commissioning of Lathe/Rolling M/c 30-May-2013 In Progress

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